FTRT.n OF THE INVENTION

This invention relates in general to control cables, and more particularly to an adjustment device for Bowden type (cable within a housing) bicycle control cables.

BACKGROUND OF THE INVENTION

Conventionally, a bicycle control cable, comprising a control wire partially encased by a sheath, is inteφosed between an operating mechanism, such as a bicycle derailleur or brake, and a control device, such as a shifter or brake lever. In the case of a bicycle derailleur, the control wire links the shifter to a derailleur having a chain guide for switching a drive chain laterally between the sprockets of a multistage sprocket assembly. Derailleur shifters are generally available in two varieties; conventional pivoting levers and rotational twist-shifters. State ofthe art twist-shifters as described in Patterson (U.S. Patent No. 4,900,291), are manufactured by SRAM Coφoration of Chicago, Illinois and marketed under the Grip Shift ^® mark.

Conventional derailleur shifters are manually actuated to laterally displace the chain guide and in turn the drive chain to the desired sprocket. With conventional friction shifters, shifts between sprockets are generally characterized by "rasping" noises as the chain is temporarily seated in the region between sprockets thereby requiring the rider to exercise skill in actuating the shifter. Index shifting mechanisms have greatly simplified the shifting process by enabling precise indexed shifts between sprockets thereby minimizing the rasping noises. In both friction and index shifters, however, repeated shifting tends to both compress the cable sheath and stretch out the control wire, resulting in a change in relative length or slack between the control wire and the cable sheath. This slack in the control cable may cause the chain guide to urge the drive chain into the "rasping" zone or may even result in undesired shifts.

Similarly, slack in brake control cables widens the gap between the brake shoes and the wheel rim thereby requiring greater brake lever deflection to initiate

braking and will generally alter the brake "feel." This may result in a potentially hazardous situation whereby a rider accustomed to brake shoe contact after deflecting the brake lever a given distance may overcompensate and unintentionally lock the brakes inducing a skid. It is therefore desirable to incoφorate an adjustment device into control cable systems to eliminate any excessive cable slack.

Generally, control cable adjustment devices, such as that illustrated in Figure 1, include a threaded adjuster screw 2 that engages a mounting member 4 having an internal threaded portion 6. The control wire 8 is. fed through the adjuster screw cable guide 10 and the mounting member cable guide 6, while the sheath 12 bears against the adjuster screw 2. Rotation ofthe adjuster screw axially displaces the adjuster screw 2 and, in turn, the cable sheath 12 relative to the mounting member 4 enabling adjustment ofthe control cable displacement.

As illustrated in Figure 1 , conventional friction type control cable adjustment devices require the use of an additional part, namely a locking nut 14, to prevent unwanted vibration or control cable induced rotation ofthe adjuster screw 2.

Additionally, such adjustment devices lack an indexing mechanism that would enable precise stepped adjustment ofthe control cable displacement as well as permit the rider to sense each stepped increment of adjustment.

Several conventional adjustment devices do, however, include an indexing device. Illustrative is the adjustment device disclosed in U.S. Patent No. 4,833,937, which is incoφorated by reference herein. In the noted reference, an axial indexing mechanism is disclosed wherein the cooperating indexing surfaces are positioned in line with the adjuster screw. Such devices, besides requiring the use of additional parts that incoφorate the indexing surfaces, are nonfunctional without the use of an additional spring element required to bias the indexing surfaces against each other.

Most significantly, existing control cable adjustment devices uniformly employ a threaded shaft on the adjuster element instead of on the mounting member. Such a configuration has several significant disadvantages. For example, the use of an adjuster screw exposes the threads and spring to the environment, permitting mud and

dirt to collect in the threads and spring coils thereby hampering or altogether preventing adjustments under field conditions. This becomes a significant problem when used on mountain bikes which are specifically designed for use in harsh off-road environments. Additionally, forced adjustment of a partially or fully jammed adjuster screw may result in the premature wear ofthe threaded surfaces on the adjuster screw and more significantly on the mounting member itself, unnecessarily prompting the premature and costly replacement of parts.

A further disadvantage of incoφorating a shaft on the adjuster element is the significantly higher thread loads inherent to an adjuster screw design as compared to an adjuster nut configuration. The adjuster element generally incoφorates a socket which seats the cable sheath thereby subjecting the adjuster to repeated, cable induced out-of-plane moment or "prying loads" during use. Additionally, significant out-of- plane moment loading results from direct impact loading ofthe adjuster, frequently occurring during off-road use.

The reduced thread loading inherent to an adjuster nut design is illustrated in

Figure 2 where an adjuster screw 96 and an adjuster nut 98 are shown threaded into a mounting member 97. The out-of-plane moment or prying load M, acting on the adjuster screw 96, is balanced by an equal and opposite moment load M', acting on the adjuster nut 98. As shown, the assembly, comprising the adjuster screw 96, the mounting member 97 and the adjuster nut 98 is in moment equilibrium, whereby the moments M, M' are transmitted to the mounting member 97 through the mounting member internal and external threads 95a, 95b receiving the adjuster screw 96 and adjuster nut 98, respectively.

Referring to Figure 3, there is shown an exploded view ofthe above noted assembly 96, 97, 98, illustrating the loads acting on each individual element 96, 97,

98. As shown, the adjuster screw 96, adjuster nut 98 and mounting member 97 are in loading equilibrium. The moment M applied to the adjuster screw 96 is balanced by equal and opposite thread forces T,, Tj' which act primarily on the outermost threads at a thread diameter D) , resulting in thread loads of magnitude T, = T, ' = M/D _| . Likewise, the adjuster nut moment M' is balanced by equal and opposite thread forces

T ₂ = T ₂ ' = M'/D ₂ acting at a thread diameter D ₂ . The thread forces T,, T,' and T ₂ , T ₂ ', in turn, act on the internal and external threads 95a, 95b of the mounting element 97, respectively, placing it in loading equilibrium as well.

The magnitude ofthe thread loads T _u T ₂ is directly proportional to the thread diameters D _h D ₂ . An adjuster nut configuration, however, couples out the same moment load M' over the larger thread diameter D ₂ . In fact, for any given mounting element configuration, switching from an internal thread design (i.e. adjuster screw) to an external thread design (i.e. adjuster nut), proportionally reduces the thread loads by the thread diameter ratio D, / D ₂ (i.e. T2 = Tl x D1/D2). These reduced thread loads are especially significant in light ofthe increasing emphasis in the bicycle industry to provide lighter weight components formed from thermoplastic, resin-based and other non-metallic materials. Because ofthe use of these lighter weight and reduced strength materials, there is a strong need to develop designs with reduced thread loading.

The substantially reduced thread loads in combination with the protective sealing benefits inherent in an adjuster nut configuration, prevents premature wear of the threads and in turn the premature and costly replacement of parts. The adjustment device ofthe present invention avoids the limitations inherent to adjuster screw designs and overcomes other problems existing in conventional control cable adjustment devices.

It is therefore an object ofthe present invention to provide a control cable adjustment device that is especially well suited for off-road use in mud and dirt environments, that substantially encases the cooperating threads and engaging portion of the protrusions and detents thereby preventing premature wear ofthe cooperating surfaces.

Another object ofthe present invention is to provide an adjustment device that significantly reduces the thread loads resulting from external moment or prying loads that are common to off-road biking.

A further object ofthe present invention is to provide an economical two piece adjustment device that embodies a simple rotational indexing mechanism based on the relative elastic deformation ofthe engaging surfaces thereby enabling the rider to sense each stepped increment of adjustment without the use of extraneous spring elements or additional cooperating parts.

ST JMMAR Y OF THE INVENTION

In accordance with the objects and advantages ofthe present invention, the control cable adjustment device ofthe present invention comprises an elongated mounting member having an outer surface and a first cable lumen adapted to receive the control wire therethrough, and an adjuster having a bore defining an inner surface.

The adjuster is adapted to rotationally mount the mounting member whereby the adjuster is axially movable relative to the mounting member in response to rotation of the adjuster. The adjuster includes a second cable lumen adapted to receive a control wire therethrough and a sheath seat adapted to position one end of a cable sheath.

The adjustment device ofthe invention further includes an indexing mechanism comprising a system of cooperating detents and protrusions. The protrusions are adapted to elastically engage and disengage the detents in response to rotation ofthe adjuster, thereby enabling stepped adjustment ofthe control cable displacement.

BRIEF DESCRIPTION OF THE DRAWINOS

The foregoing objectives, advantages and features ofthe invention and those which will be apparent below can be better appreciated after review ofthe following detailed descriptions, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals and wherein:

FIGURE 1 is an expanded isometric view of a prior art control cable adjustment device;

FIGURE 2 is a sectional view of an assembly comprising an adjuster screw, an adjuster nut and a mounting element;

FIGURE 3 is an expanded sectional view ofthe elements illustrated in FIGURE 2;

FIGURE 4 is an isometric view of an embodiment of the invention in combination with a shifter mechanism linked to a derailleur mechanism;

FIGURE 5 is an expanded isometric view ofthe cooperating elements ofthe adjustment device ofthe invention in a shifter embodiment;

FIGURE 6 is an expanded isometric view ofthe cooperating elements ofthe adjustment device ofthe invention in a brake lever embodiment;

FIGURE 7 is an isometric cutaway view of an adjuster nut embodiment of the present invention;

FIGURE 8 is a sectional view of an adjuster nut and mounting member embodiment ofthe present invention taken on line A-A of FIGURE 4;

FIGURES 8a and 8b are sectional views ofthe adjuster nut and mounting member embodiment shown in FIGURE 8 taken on line A'-A' of FIGURE 4, illustrating the deformation characteristics and mechanisms according to the invention;

FIGURE 9 is a sectional view of an additional adjuster nut and mounting member embodiment of the present invention taken on line A-A of FIGURE 4; and

FIGURE 10 is a plan view of detail X of FIGURE 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Figure 4 illustrates a typical embodiment ofthe invention shown in combination with a bicycle twist-shifter 20 linked to a derailleur 24. A bicycle control

cable 18 comprising an outer sheath 12 encasing a control wire 8, operatively links the shifter 20 to the derailleur 24. The control wire 8, which preferably is a multi-filament alloy or steel cable, is ofthe Bowden type.

Figure 5 illustrates the cooperating elements ofthe adjustment device of the present invention in a shifter embodiment. Shifter 20 includes a mounting member 4 having a threaded shaft 30, a plurality of protrusions 32 formed circumferentially on the mounting member outer surface and an insertion bore 34 for receiving the control wire 8.

Figure 7 is an isometric cutaway view ofthe adjuster nut ofthe invention. The adjuster nut 40 includes a threaded bore 42 that cooperates with the threaded shaft 30 ofthe mounting member 4, a plurality of protrusions 44 formed on the adjuster nut inner surface 43 that rotatably engage and disengage the mounting member protrusions 32 and an insertion bore 46 for receiving the control wire 8. In a preferred embodiment, the adjuster nut protrusions 44 comprise longitudinal ribs extending from the adjuster nut outer end 45 to the threaded bore 42. The adjuster nut 40 and mounting member 4 are preferably formed from thermoplastic material.

In another preferred embodiment, the adjuster nut 40 includes a socket 48 which seats the cable sheath 12 (See Figure 4) and a ribbed outer surface 50 to enhance grip when rotating the adjuster nut 40. The adjustment device, which in Figure 4 is shown attached to the shifter 20 (i.e., operating mechanism), may in additional embodiments not shown be incoφorated on the bicycle derailleur or operating device.

As illustrated in Figures 4 and 5, the control wire 8, which is fed through the insertion bores 46, 34 ofthe adjuster nut 40 and the mounting member 4, is operatively connected at one end to the derailleur 24 and at its other end to the shifter 20. The sheath 12, which is seated in the adjuster nut socket 48 at one end, is fixed to the bicycle frame at its other end (not shown).

In operation, repeated derailleur shifts compress the sheath 12 and stretch the control wire 8. This relative change in length or "slack" between the control sheath 12 and the control wire 8 is offset by manual rotation ofthe adjuster nut 40 which axially displaces both the adjuster nut 40 and the sheath 12 relative to the mounting member 4 thereby removing the slack in the control cable 18. According to the invention, rotation ofthe adjuster nut 40 causes the mounting member protrusions 32 to engage and disengage, through relative elastic deformation, the adjuster nut protrusions 44 thereby enabling the rider to sense each stepped or indexed increment of adjustment. The adjuster nut 40 is also designed and configured to substantially enclose both the cooperating threaded surfaces 30, 42 as well as the engaging portion ofthe protrusions

32, 44 over the entire range of motion ofthe adjuster nut 40 along the mounting member 4, thereby protecting the cooperating surfaces from external particles which may become trapped between the threaded surfaces.

In additional embodiments, a bellows sealably connecting the adjuster outer surface 41 and mounting member outer surface 5, may be used to protectively encase the cooperating threads and engaging protrusions and detents. Protection of the cooperating surfaces is of paramount concern in off-road biking environments where exposed threads tend to trap mud and dirt particles which are then ground between the cooperating threaded surfaces as control cable adjustments are made under field conditions thereby leading to the premature wear and replacement of parts.

Figure 6 illustrates the adjustment device ofthe invention in a brake lever embodiment. A brake lever mechanism is characterized by the use of a cable end 60 disposed on the end ofthe control wire 8, the cable end 60 being operatively connected to the pivoting lever 62. To facilitate the installation of a control wire 8 having a cable end 60, slots 64, 66 are formed in the adjuster nut 40 and the mounting member 4. The presence of the slot 64 along the length of adjuster nut 40 reduces the radial and bending stiffness ofthe adjuster nut wall. This, in turn, reduces the rotational resistance of the indexing mechanism thereby requiring the use of a thicker adjuster nut wall or stiffer material.

As illustrated in Figure 8, the mounting member 4 ofthe invention includes a plurality of protrusions 32 disposed on the outer surface 33 thereof. According to the invention, the mounting member protrusions 32 define a plurality of first deformable regions 35.

As will be appreciated by one having skill in the art, one or more mounting member protrusions 32 may be employed within the scope ofthe invention. However, in a preferred embodiment, two protrusions 32 are disposed on the mounting member outer surface 33.

The adjuster nut 40 includes an indexing portion 41 comprising a plurality of engaging detents 44 adapted to engage the mounting member protrusions 32 and a plurality of second deformable regions 37 disposed between the engaging detents 44. In operation, the engagement ofthe protrusions 32 and detents 44 maintains the adjuster nut 40 position on the mounting member 4.

As illustrated in Figure 8a, according to the invention, when the adjuster nut 40 is rotated a given angle γ relative to the mounting member 4, the mounting member protrusions 32 and the adjuster stop detents 44 disengage, the first and second deformable regions 35, 37 slidably cooperate, and the first deformable region 35 exhibits a first deformation while the second deformable region 37 exhibits a second deformation.

Applicant has found that optimum performance of the control cable adjustment device is achieved when the second deformation (i.e. adjuster nut) is greater than the first deformation, such as that illustrated in Fig 8a. Accordingly, in a preferred embodiment the Modulus of Elasticity for the first and second deformable region is in the range of approximately 200,000 psi to 30,000,000 psi, more preferably in the of approximately 300,000 psi to 1 ,000,000 psi.

According to the noted preferred embodiment ofthe invention, when the adjuster nut 40 is rotated and the protrusions 32 transition between respective engaging detents 44, the shape ofthe nut 40 undergoes a slight transition from (i) a

substantially circular shape, to (ii) an oval shape, and returns to (iii) a substantially circular shape. The relative shape ofthe adjuster nut 40 through the noted transition will of course depend on the Modulus of Elasticity ofthe first and second deformable regions.

As will be appreciated by one having skill in the art, the first and second deformable regions may be designed and configured to achieve optimum first and second deformations, resistance forces (as discussed below) and, hence, "user feel". For example, in additional embodiments ofthe invention, as illustrated in Figure 8b, the first and second deformations are substantially equal. In additional embodiments, not shown, the first deformation is greater than the second deformation.

In additional embodiments ofthe invention, not shown, the adjuster nut 40 may include a plurality of protrusions and the mounting member may include a plurality of engaging detents adapted to engage the adjuster nut protrusions. In operation, such a configuration may be adapted to exhibit similar deformation characteristics as that detailed above.

Figure 9 is a sectional view taken on line A-A of Figure 4 showing an additional preferred adjustment device embodiment exhibiting differing rotational resistances for each direction of rotation. Upon installation ofthe adjustment device in a control cable system, slack in the control cable is removed by rotation of the adjuster nut 40 such that the adjuster nut 40 is displaced away from the mounting member 4.

Therefore, in an additional embodiment the rotational indexing resistance displacing the adjuster nut 40 axially away from the mounting member 4 may be reduced relative to the rotational indexing resistance in the opposite direction. This differing rotational resistance may be achieved, as shown in Figure 10, by using protrusions 32 having sloping surfaces 70, 72 with correspondingly distinct angles 2 _{1 ?} 2 ₂ with respect to radial lines 74. As the sloping surfaces 70, 72 engage their respective cooperating surfaces 71, 73, which partially define the detent 75, differing rotational indexing resistances result in response to rotation ofthe adjuster nut 40 in the clockwise versus counterclockwise directions.

The adjuster nut 40 elastic resistance to the combined radial and bending deformation induced by the indexing engagements is greatest at the center ofthe adjuster nut and decreases towards the adjuster nut outer end 45. This increasing flexibility towards the adjuster nut outer end 45 results in a correspondingly decreasing resistance to rotation as the nut is displaced axially away from the mounting member. The varying rotational resistance for rotation in a given direction may be offset by correspondingly varying the slope ofthe cooperating surfaces 70, 71 and 72, 73 along the length ofthe engaging protrusions 32 and detents 75. Such a change will offset the reducing adjuster nut radial and bending stiffness with a correspondingly increasing engagement resistance achieved by increasing the slope of the cooperating indexing surfaces 70,71 and 72, 73. In the embodiment of Figure 10, this counterbalancing effect can be achieved by defining angles 2 _b 2 ₂ at their maximum values at the end ofthe protrusions 32 and detents 75 closest to the center ofthe adjuster nut and correspondingly reducing angles 2,, 2 ₂ (i.e. increasing slope) towards the adj uster nut outer end 45.

In yet another embodiment, the adjuster nut 40 may cooperate with the mounting member 4 without the use of cooperating threads 30, 42. Additional embodiments may incoφorate a stepped pattern of incremental axial and rotational displacements between the adjuster nut 40 and the mounting member 4 (not shown), thereby achieving a similar cooperating relationship between the adjuster nut 40 and the mounting member 4.

Accordingly, it will be appreciated by a person having ordinary skill in the art that the adjustment device of this invention embodies a simple and economical two piece device for offsetting slack in a control cable that substantially encases and protects the engaging surfaces from environmental exposure while significantly reducing the thread loading resulting from external out-of-plane moment loads. In addition, the adjustment device efficiently incoφorates within its two piece configuration a simple rotational indexing mechanism based on the relative elastic deformation ofthe engaging surfaces that effectively enables the rider to sense each stepped increment of adjustment without resorting to a spring biased design.

Although the invention has been described with reference to several different embodiments, these embodiments are merely exemplary and not limiting ofthe invention which is defined by the appended claims.